Telescopic ballscrew actuator

ABSTRACT

An apparatus for a thrust reverser actuation system (“TRAS”), the apparatus comprising: an input shaft; a first component located concentrically around the input shaft; a second component located concentrically around the first component; a first ballscrew mechanism between the input shaft and the first component, and configured such that rotational movement of the input shaft causes a translational movement of the first component via the first ballscrew mechanism; and a second ballscrew mechanism between the first component and the second component, and configured such that rotational movement of the first component causes a translational movement of the second component via the second ballscrew mechanism.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/016,778 filed Jun. 25, 2018, which claims priority to European PatentApplication No. 17178314.5 filed Jun. 28, 2017, the disclosures of whichare incorporated herein by reference in their entirety.

FIELD

The present disclosure relates generally to actuators for use inaerospace applications (e.g., an aircraft), such as a thrust reverseractuation systems (“TRAS”) and/or a variable area fan nozzle (“VAFN”),and specifically a new type of telescopic ballscrew actuator for use insuch systems.

BACKGROUND

Thrust reversers are provided on jet engines typically to increase theamount of braking on an aircraft upon landing. When deployed, a thrustreverser will change the direction of thrust of the jet engine such thatsome or all of the thrust is directed forwards, which acts to slow theaircraft so that it can then taxi off the runway.

There are a number of types of thrust reverser, all of which must bestowed during normal aircraft operation, for example so that the thrustreverser cannot be deployed during take-off or at a cruise altitude andcan only be deployed during landing. In order to ensure this, one ormore lock members are provided to prevent unwanted deployment of thethrust reverser, and in particular the actuators that move the variousparts of the thrust reverser assembly.

New aerospace engine nacelle systems are being developed to increaseengine efficiency (e.g., increased fuel burn with reduced drag) andreduce engine emissions (noise). To support these new types of nacelle,new nacelle architectures (e.g., reduced length) and systemconfigurations (e.g., alternative thrust reverser kinematics) are beingdesigned and developed. These new nacelle architectures and systemsrequire the thrust reverser actuation system to be fitted into asignificantly smaller installation envelope on the nacelle, whilstproviding increased stow and deploy strokes, all the while maintainingthe performance characteristics of previous systems.

It is desired to improve the actuator in a thrust reverser actuationsystem, and this is the aim of the present disclosure.

SUMMARY

In accordance with the invention, there is provided an apparatus for usein an aircraft (e.g., an aircraft thrust reverser), the apparatuscomprising: an input shaft; a first component located concentricallyaround the input shaft; a second component located concentrically aroundthe first component; a first ballscrew mechanism between the input shaftand the first component, and configured such that rotational movement ofthe input shaft causes a translational movement of the first componentvia the first ballscrew mechanism; and a second ballscrew mechanismbetween the first component and the second component, and configuredsuch that rotational movement of the first component causes atranslational movement of the second component via the second ballscrewmechanism.

The first ballscrew mechanism may comprise a screw thread located on anouter surface of the input shaft and a cooperating screw thread locatedon an inner surface of the first component.

The outer surface of the input shaft and the inner surface of the firstcomponent may be circumferential surfaces of the input shaft and thefirst component, respectively.

The second ballscrew mechanism may comprise a screw thread located on anouter surface of the first component and a cooperating screw threadlocated on an inner surface of the second component.

The outer surface of the first component and the inner surface of thesecond component may be circumferential surfaces of the first componentand the second component, respectively.

The input shaft may be fixed against axial movement.

In a first mode the first component may be configured to translate alongan axis upon rotational movement of the input shaft, and in a secondmode the first component may be configured to rotate about the axis.

In the first mode the second component may be configured to translatewith the first component along the axis.

In the second mode the second component may be configured to translatealong the axis due to the operation of the second ballscrew mechanism.

A stop may be located on the first component that is configured, in thefirst mode, to abut the second component so as to cause the secondcomponent to translate with it along the axis as aforesaid.

The apparatus may be configured such that the first mode and the secondmode occur sequentially, so as to provide two separate and distincttranslational movements of the second component.

The first mode may occur prior to the second mode, and a transitionbetween the first mode and the second mode may be caused by a stopattached to the first component abutting a stop attached to the inputshaft, which abutment prevents further translation of the firstcomponent such that further rotational movement of the input shaftcauses the first component to start rotating and the second component totranslate along the axis due to the operation of the second ballscrewmechanism.

The second mode may occur prior to the first mode, and the transitionbetween the second mode and the first mode may be caused by a stopattached to the second component abutting a stop attached to the firstcomponent, which abutment prevents further translation of the secondcomponent such that further rotational movement of the input shaftcauses the first component to start translating and the second componentto translate with it along the axis.

References to “translating” and “rotating” as used herein and above maybe with reference to the longitudinal axis of any one of the inputshaft, first component, second component, first ballscrew mechanism orsecond ballscrew mechanism. The input shaft, first component, secondcomponent, first ballscrew mechanism and second ballscrew mechanism mayall comprise the same longitudinal axis.

In accordance with the invention, there is provided an actuator for anaircraft and comprising an apparatus as described above and herein.

In accordance with the invention, there is provided a thrust reverseractuation system (“TRAS”) or variable area fan nozzle (“VAFN”)comprising an apparatus as described above and herein.

In accordance with the invention, there is provided a method ofoperating an actuator of an aircraft, comprising: rotating an inputshaft of the actuator about an axis to cause a first component totranslate along the axis due to operation of a first ballscrewmechanism; and rotating the first component about the axis to cause asecond component to translate along the axis due to operation of asecond ballscrew mechanism.

The actuator may be part of an apparatus as described above.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments will now be described, by way of example only, andwith reference to the accompanying drawings in which:

FIG. 1 shows schematically an embodiment of the present disclosure;

FIG. 2 shows an embodiment of the present disclosure in further detail;

FIG. 3 shows a conventional arrangement; and

FIG. 4 shows the embodiment of FIG. 2 as it fits into a thrust reverseractuator.

DETAILED DESCRIPTION

The broad concept of the present disclosure is a thrust reverseractuator that utilises two ballscrew components that are arrangedconcentrically and achieve a defined actuator stroke, with a reducedinstallation length compared to existing technologies.

Conventional technologies may use only a single ballscrew component toachieve a given actuator stroke, and the presently described technologyallows the thrust reverser actuator to be fitted in a shorterinstallation envelope offering size benefits to the engine nacellewhilst maintaining its performance characteristics.

FIG. 1 shows an embodiment of the present disclosure, in which anapparatus 1 comprises an input shaft 10 that is rotatable about an axisA in a rotational direction 2. The input shaft 10 may be a rotatingdriveshaft of an actuator, and the axis A may be the longitudinal axisand/or rotational axis of the actuator. The input shaft 10 may be fixedin an axial direction, and may comprise a screw thread 12 that extendsaround an outer surface 14 of the input shaft 10.

A first component 20 is located concentrically around the input shaft10, and a first ballscrew mechanism 22 is provided such that rotation ofthe input shaft 10 applies a force to the first component 20 in adirection of actuation 3, via the first ballscrew mechanism 22, toactuate a component (e.g., deploy a thrust reverser cowl). As will bediscussed in more detail below, this will cause the first component 20to move, either axially along the axis A, or rotationally around theaxis A to drive the component.

The first component 20 comprises a first screw thread 24 that extendsaround an inner surface 25 of the first component 20. Thus, the firstballscrew mechanism 22 comprises the screw thread 12 of the input shaft10, as well as the first screw thread 24 of the first component 20. Uponrotation of the input shaft 10, the first ballscrew mechanism 22 willoperate by forcing balls of the first ballscrew mechanism 22 around atrack formed by the screw thread 12 of the input shaft 10 and the firstscrew thread 24 of the first component 20. As is known, the balls may becaptured and recycled (e.g., through recycling tubes), as the firstcomponent 20 translates along the axis A.

The first component 20 further comprises a second screw thread 26 thatextends around an outer surface 27 of the first component 20, and formspart of a second ballscrew mechanism 32 (described below).

A second component 30 is located concentrically around the input shaft10 and the first component 20. A second ballscrew mechanism 32 isprovided, which is formed by the second screw thread 26 of the firstcomponent 20 and a screw thread 34 that extends around an inner surface36 of the second component 30.

The second component 30 is fixed against rotational movement, and assuch will be caused to move in the direction of actuation 3 upon axialor rotational movement of the first component 20. That is, upon axial orrotational movement of the first component 20, the first component 20will apply an axial force to the second component 30 via the secondballscrew mechanism 32.

If the first component 20 is translating (as opposed to rotating) alongthe axis A, then the second component 30 will also move axially with thefirst component 20.

If the first component 20 is rotating, then the second ballscrewmechanism 32 will operate by forcing the balls of the ballscrewmechanism around a track formed by the second screw thread 26 of thefirst component and the screw thread 34 of the second component 30. Theballs may be captured and recycled (e.g., through recycling tubes) as isknown generally in the art.

As briefly discussed above, due to the configuration of the apparatus 1described above, different operational sequences may occur upon rotationof the input shaft 10 depending mainly on the frictional forces betweenthe various components.

In a first operational sequence, input rotation may be provided (e.g.,by an electric or hydraulic motor) to the input shaft 10. Rotation ofthe input shaft 10, which is axially fixed, may result in translation ofthe first component 20 via the first ballscrew mechanism 22. Translationof first component 20 results in translation of the second component 30(which is rotationally fixed) via the second ballscrew mechanism 32. Thesecond ballscrew mechanism 32 may be restrained in rotation, forexample, by a clevis attachment to a fixed structure (e.g., a fixednacelle). Translation of the second component 30 results in translationof the component to which the actuator is attached.

In the second operational sequence, rotation of the input shaft 10 mayresult in rotation of the first component 20 (rather than translation asdiscussed above), which means that the second component 30 is initiallydriven to translate along the axis A by the translation of the firstcomponent 20. Subsequently, and once the first component 20 reaches theend of its travel (e.g., reaches a stopper as described below), thefirst component 20 will begin to rotate, resulting in furthertranslation of the second component 30 due to the rotation of the firstcomponent 20.

It will be appreciated that the operational sequences of the apparatus 1are not limited to the first and second operational sequences discussedabove, and it is possible that operational sequences of the apparatus 1involve other sequences.

In any of the operational sequences, the first component 20 and thesecond component 30 each have a certain amount of travel. However,translations of the first component 20 and the second component 30 donot have to occur sequentially, as described above. Rather, theapparatus 1 may be configured such that the translations of the firstcomponent 20 and the second component 30 alternate a plurality of timesduring rotation of the input shaft 10 to actuate the component.

FIG. 2 shows an embodiment of the present disclosure in further detail,and within an actuator assembly 50, which houses the apparatus 1.Reference numerals in FIG. 2 correspond to the same components as thosedescribed with the same reference numerals in respect of FIG. 1.

As can be seen from FIG. 2, the apparatus 1 fits inside the actuatorassembly 50, with the second component 30 being slidably received withinan extended portion 52 of the actuator assembly 50. The first component20 is also contained within the extended portion 52, and the input shaft10 is partially received within the extended portion 52.

In use, the first component 20 and the second component 30 protrude andextend from an open end 54 of the actuator assembly 50. As discussedabove, the input shaft 10 is fixed against axial movement and does notchange its axial position with respect to the extended portion 52.

In order to control the translation of the first component 20 and thesecond component 30, and plurality of stops are provided. Each stop isfixed to one of the input shaft 10, first component 20 and secondcomponent 30, and cooperates with another stop to limit the stroke ofeach of the first component 20 and the second component 30.

The discussion/example below assumes that the apparatus 1 operates inline with the first operational sequence described above.

A first stop 39 is connected to the first component 20 and may belocated around the outer surface 27 of the first component 20 and/oraxially between the first ballscrew mechanism 22 and the second screwshaft 26 of the first component 20. The first stop 39 is configured toabut the second component 30 such that translation of the firstcomponent 20 along the axis A (i.e., upon rotation of the input shaft10) causes the second component 30 to translate along the axis A.

A second stop 40 is connected to the input shaft 10, for example at adistal end 16 thereof, and cooperates with a third stop 42 that isconnected to the first component 20 (e.g., at an inner surface thereofand adjacent to the first ballscrew mechanism 22).

As the first component 20 moves in the direction of actuation 3, thethird stop 42 moves progressively closer to the second stop 40 and willeventually abut the second stop 40. At this point, further movement ofthe first component 20 in the direction of actuation 3 is prevented,since the second stop 40 is connected to the input shaft 10, which isfixed against axial movement (i.e., along axis A). As such, the firstcomponent 20 will begin to rotate due to the engagement of the secondstop 40 and the third stop 42, resulting in axial movement of the secondcomponent 30 (which, as discussed above, is fixed against rotationalmovement).

A fourth stop 44 is connected to the first component 20 (e.g., at anouter surface thereof), for example at the end of the second screwthread 26 of the first component 20, and cooperates with a fifth stop 46that is connected to the second component 30 (e.g., as an inner surfacethereof and adjacent to the second ballscrew mechanism 32).

Continued rotation of the input shaft 10, and first component 20 causesthe second component 30 continue to translate in the direction ofactuation 3, such that the fifth stop 46 moves progressively closer tothe fourth stop 44 and eventually abuts the fourth stop 44 once thesecond component 30 has reached its maximum stroke.

It will be appreciated that the same arrangement can operate in thesecond operational sequence described above. This would depend on thefrictional forces between the various components.

For example, if input shaft 10 rotates and passes a load to the firstcomponent 20 via the first ballscrew mechanism 22, it may be that theload is not enough to overcome the frictional forces (which may dependon the design of the particular ballscrew mechanism used) between thescrew thread 12 of the input shaft 10 and the first screw thread 24 ofthe first component 20, and other parts of the first ballscrewmechanism, e.g., the balls. In this case, the load may be passed to thesecond ballscrew mechanism 32. If the frictional forces between thecomponents of the second ballscrew mechanism 32 are sufficiently small,then the first component 20 will initially rotate with the input shaft10, causing the second component 30 to translate along the axis A.

The second component 30 may translate until the fifth stop 46 reachesthe fourth stop 44, at which point the load passed to the secondballscrew mechanism 32 cannot translate the second component 30, and therotation of the input shaft 10 will begin to translate, rather thanrotate the first component 10. The first component 20 will thentranslate along the axis A until the third stop 42 reaches the secondstop 40. At this point the actuator will have reached its maximum stroke(which is the same for either operational sequence).

As will be appreciated, the translation of the second component 30 maybe effectuated in two modes of operation. In a first mode, the firstcomponent 20 may translate upon rotation of the input shaft 10, causingthe second component to translate, either using a stop (e.g., first stop39) as in the first operational sequence, or using relative frictionalforces between the ballscrew mechanisms as in the second operationalsequence. In a second mode, the first component 20 may rotate uponrotation of the input shaft 10, causing the second component 30 totranslate via the ballscrew arrangement of the first ballscrew mechanism22.

Regardless of the sequence of the above modes of operation, the overallstroke of the actuator, and the stroke of the actuator during eithermode of operation will be the same.

This telescopic arrangement means that the extended portion 52 of theactuator assembly 50 can be fitted in a shorter installation envelopethan conventional arrangements that do not utilise multiple ballscrewmechanisms, offering size benefits to the engine nacelle whilstmaintaining its performance characteristics.

It will be appreciated that the present disclosure is not limited to theuse of two ballscrew mechanisms, and it is possible that any number ofballscrew components may be provided, with suitable ballscrew mechanismsbetween adjacent ballscrew components (in the same manner as describedabove in respect of FIGS. 1 and 2), to achieve a defined actuator strokedepending on the installation envelope and specific requirements ofparticular systems.

FIG. 3 shows an example of a conventional actuator 100 that uses asingle ballscrew component, which may have an installation length 1 ofabout 39 inches, and a stroke s of about 28 inches.

FIG. 4 shows an example of an actuator assembly 50 in accordance withthe present disclosure (e.g., corresponding to the actuator assembly 50described above in respect of FIG. 2) that has an installation length Lof about 27 inches, and a stroke S equal to that of the conventionalactuator 100 of about 28 inches.

Although the present invention has been described with reference topreferred embodiments, it will be understood by those skilled in the artthat various changes in form and detail may be made without departingfrom the scope of the invention as set forth in the accompanying claims.For example, and as discussed above, any number of ballscrew componentsand ballscrew mechanisms may be used to provide a telescopic actuatorthat reduces the installation length of a previously employedconventional actuator.

Furthermore, the technology disclosed herein may be used in otheraircraft or aerospace applications, for example a variable area fannozzle (“VAFN”) or other nacelle actuation systems.

What is claimed is:
 1. An apparatus for use in an aircraft, theapparatus comprising: an input shaft; a first component locatedconcentrically around the input shaft; a second component locatedconcentrically around the first component; a first ballscrew mechanismbetween the input shaft and the first component, and configured suchthat rotational movement of the input shaft causes a translationalmovement of the first component via the first ballscrew mechanism; and asecond ballscrew mechanism between the first component and the secondcomponent, and configured such that rotational movement of the firstcomponent causes a translational movement of the second component viathe second ballscrew mechanism; wherein in a first mode the firstcomponent is configured to translate along an axis upon rotationalmovement of the input shaft, and in a second mode the first component isconfigured to rotate about the axis; wherein the first mode occurs priorto the second mode, and a transition between the first mode and thesecond mode is caused by a stop fixedly attached to the first componentabutting a stop fixedly attached to the input shaft to limit the strokeof the first component, which abutment prevents further translation ofthe first component such that further rotational movement of the inputshaft causes the first component to start rotating and the secondcomponent to translate along the axis due to the operation of the secondballscrew mechanism.
 2. An apparatus as claimed in claim 1, wherein thefirst ballscrew mechanism comprises a screw thread located on an outersurface of the input shaft and a cooperating screw thread located on aninner surface of the first component.
 3. An apparatus as claimed inclaim 2, wherein the outer surface of the input shaft and the innersurface of the first component are circumferential surfaces of the inputshaft and the first component, respectively.
 4. An apparatus as claimedin claim 1, wherein the second ballscrew mechanism comprises a screwthread located on an outer surface of the first component and acooperating screw thread located on an inner surface of the secondcomponent.
 5. An apparatus as claimed in claim 4, wherein the outersurface of the first component and the inner surface of the secondcomponent are circumferential surfaces of the first component and thesecond component, respectively.
 6. An apparatus as claimed in claim 1,wherein the input shaft is fixed against axial movement.
 7. An apparatusas claimed in claim 1, wherein in the first mode the second componenttranslates with the first component along the axis, and in the secondmode the second component translates along the axis due to the operationof the second ballscrew mechanism.
 8. An apparatus as claimed in claim1, wherein the apparatus is configured such that the first mode and thesecond mode occur sequentially, so as to provide two separatetranslational movements of the second component.
 9. An apparatus asclaimed in claim 1, comprising an actuator assembly wherein, in use, thefirst component and the second component protrude and extend from anopen end of the actuator assembly.
 10. An actuator for an aircraft andcomprising an apparatus as claimed in claim
 1. 11. A thrust reverseractuation system (“TRAS”) or variable area fan nozzle (“VAFN”)comprising an apparatus as claimed in claim
 1. 12. A method of operatingan actuator of an aircraft, comprising: in a first mode, rotating aninput shaft of the actuator about an axis to cause a first component totranslate along the axis due to operation of a first ballscrew mechanismso that the first component telescopically protrudes and extends fromthe input shaft; in a second mode, rotating the first component aboutthe axis to cause a second component to translate along the axis due tooperation of a second ballscrew mechanism so that the second componenttelescopically protrudes and extends from the first component; andwherein the first mode occurs prior to the second mode and transitioningbetween the first mode and the second mode by a stop fixedly attached tothe first component abutting a stop attached to the input shaft to limitthe stroke of the first component, thereby preventing furthertranslation of the first component such that further rotational movementof the input shaft causes the first component to start rotating and thesecond component to translate along the axis due to operation of thesecond ballscrew mechanism.
 13. An actuator for use in an aircraft, theactuator comprising: an input shaft; a first component locatedconcentrically around the input shaft; a first ballscrew mechanismbetween the input shaft and the first component, and configured suchthat in a first mode rotational movement of the input shaft passes aload to the first component via the first ballscrew mechanism , whereinthe load overcomes frictional forces between the input shaft, the firstcomponent and the first ballscrew mechanism, so as to cause atranslational movement of the first component via the first ballscrewmechanism; characterised in that the actuator comprises: a secondcomponent located concentrically around the first component; and asecond ballscrew mechanism between the first component and the secondcomponent, and configured such that in a second mode rotational movementof the input shaft passes a load to the first component via the firstballscrew mechanism, wherein the load does not overcome frictionalforces between the input shaft, the first component and the firstballscrew mechanism so as to cause a rotational movement of the firstcomponent which passes the load to the second ballscrew mechanism and socauses a translational movement of the second component via the secondballscrew mechanism, wherein in the first mode the first component isconfigured to translate along an axis upon rotational movement of theinput shaft, and in the second mode the first component is configured torotate about the axis, wherein an operational sequence of the first modeand the second mode is caused by said frictional forces between theinput shaft, the first component and the first ballscrew mechanism. 14.A method of operating an actuator of an aircraft, comprising: in a firstmode, rotating an input shaft of the actuator about an axis to pass aload to a first component via a first ballscrew mechanism, the loadovercoming frictional forces between the input shaft, the firstcomponent and the first ballscrew mechanism so as to cause the firstcomponent to translate along the axis due to operation of the firstballscrew mechanism; and in a second mode, rotating the input shaft topass a load to the first component via the first ballscrew mechanism,wherein the load does not overcome frictional forces between the inputshaft, the first component and the first ballscrew mechanism therebyrotating the first component about the axis to cause a second componentto translate along the axis due to operation of a second ballscrewmechanism, wherein an operational sequence of the first mode and thesecond mode is caused by relative frictional forces between the firstballscrew mechanism and the second ballscrew mechanism.